Cracked Front Headlight
 

I have 31,000 kms on my 04 RX8 and 3 weeks ago I noticed moisture in my passenger side headlight. I looked and found that the plastic had cracked on the upper right portion of the headlight and there is no damage (ie rock damage) on the plastic itself. The crack is situated just under the hood. Service manager looked at the crack and agreed that it wasn't caused by debris hitting it, so he said he would call Mazda Canada and see if there is a service bulletin on it. I went yesterday to get it fixed and the service manager is telling me since no service bulletin on the headlight that it is going to be fixed under warranty. The price to replace is $700.00. I had another mechanic look at it and he seems to think it is either a stress crack or caused by cloing of the hood. Anyway, no way am I going to pay $700 for a new headlight so I am calling Mazda Canada today to see what they think.

Just to put this into perspective. I have already had both my rear taillights replaced due to stress cracks on the car.

Cheers
ALT

I assume you meant to say "It is NOT going to be fixed under warranty"? If so, I wasn't aware that you needed a TSB to get a warranty repair. It just has to be something that is not expected from normal wear and tear. Ie: it is normal to open and close your hood, so if that cracks your headlight, something was not manufactured properly and it is a warranty item. I think you need a better explanation for why this is not a warranty repair!

This sounds like it's going to be hard to prove that it's a warranty issue.
But the stress cracks in the rears that are documented might give you some small help.
Good luck.

Well; I called Mazda Canada and they are the same point as the Service Manager, they haven't heard of this problem yet so no warranty coverage. I called back the Service Manager and he indicated that he was going to talk with the Regional Manager and see if anything could be done given the previous problems. So I am crossing my fingers.

if need be to correct the problem is take the assembly off myself and remove all the moisture and seal it with clear silicon and hope the crack doesn't spread.

so its a waiting game.

Cheers
ALT

THINGS FIXED ON MY RX8 to DATE:

New oil pan - recall
2 new tail light assemblies - stress cracks - warranty
2 ECM upgrades - TSB's
4 new tires - warranty
New oil dipstick - TSB
New front brakes - TSB
Temp control dial replaced - TSB